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08KLR650installation.pdf

KLR 650 Rack & Luggage Installation ('08-'18)

 

Items provided:

 

• Saddlebags

• ABS rack (comes pre-assembled)

• Hardware (metric) 13 pieces [Figure 1]

A (2) B C
35mm bolt 110mm bolt 100mm bolt
washer washer washer
  shim spacer
  spacer locknut
  locknut  
     
Top Right Left

 

Tools needed:

 

• Ratchet

• 8mm, 10mm, and 13mm sockets

• 13mm wrench

• 6mm allen wrench

 

Assembly required: Mount the ABS rack to the subframe of the KLR with the provided hardware. Then secure the saddlebags into place.

 

Note: Spacers/shims included with rack are black. White spacers pictured are for photo purposes only.

Detailed instructions are shown below.

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Step 1 - Remove Stock (OEM) Bolts:

 

First, check that the two bolts immediately behind the storage compartment are tight. The stock bolts need to be removed so the new mounting hardware can replace it. Figure 2 and 3 show the location of the two A bolts, B bolt, and C bolt that need to be removed.

 

Make sure the metal washers in between the stock rack and the rear fender are still in place (located behind B and C).

 

Step 2 - Put ABS Rack On:

 

You will find that the ABS rack will only fit one direction.

 

It might be easier to put the A bolts in first as they do not have as many pieces to line up. The bolt head and the big washer should be on the outside (top) of the rack.

 

Install the hardware provided loosely at first until all the bolts have been started. The bolt head, a washer, and shim should all be on the outside of the rack for bolt B. The B shim should have its thickest side on the top with the angled end against the rack. The B spacer should be placed in between the OEM rack and the ABS rack with the slanted side facing the ABS rack (Figure 5). Rotate it so the long end is on the bottom. The C spacer is square on each end and fits against the aluminum support brace.

 

Step 3 - Securing The Rack:

 

With all of the hardware lined up with the appropriate holes, you can start tightening up the bolts. You may need to manually rotate the B spacer while tightening the bolt, so the two angles match. The longer side of the spacer should be on the bottom for proper fit (rotated opposite of the shim). The B and C bolts have locknuts. Figure 4 shows the location of the C locknut.

Step 4 - Securing The Saddlebags:

 

Fisher Saddlebags™ do not use long straps with hooks to secure the saddlebags because of the potential for the strap to come loose and get caught in the wheel or chain. Instead the saddlebags are secured to the ABS rack with sewn in pockets and turn-buckles.

 

The top bag is secured by a pocket in the back that slips over the back end of the rack. Since it is sewn to the other two bags, it needs no other fastening devices.

 

The side saddlebags have a front inside pocket that slips over the front of the ABS rack. There is a single turn-buckle at the front of each saddlebag on the inside (Figure 6). There is also a flap in the back that secures to the turn-buckles mounted on the rack. Figure 7 shows this in detail.

 

With the rack bolted on to the subframe, the bags will be easy to put on. The simplest way to put the bags on is to:

 

1. Slip the top bag pocket over the back of rack
2. Secure the front left saddlebag turn-buckle
3. Slip the left saddlebag pocket over the rack
4. Repeat steps 2 and 3 for right saddlebag   
5. Fold the back flaps over the 4 turn-buckles and

....twist each turn-buckle 90 degrees

 

The ABS rack can be installed or removed in a few minutes.

 

The saddlebags can easily be installed or removed in less than a minute.

 

*If there is a lot of weight in the saddlebags, it is a good idea to strap a bungee cord around to keep the bags more stable.

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